Composite intake manifold assembly for an internal combustion engine and method for producing same

ABSTRACT

A composite air intake manifold assembly adapted for use with an internal combustion engine includes an upper half shell formed from a polymer, a lower half shell formed from a polymer and joined to the upper half shell to define a housing having an internal cavity, and a one piece inner shell formed from a polymer and disposed within the cavity. The one piece inner shell in combination with the upper half shell and the lower half shell cooperate to define at least a pair of spaced apart air intake runners. Each of the runners includes an opened air intake end adapted to receive atmospheric air, and an opened air inlet end adapted to be connected to an associated air inlet side of a cylinder head of the internal combustion engine. The method for producing the composite air intake manifold assembly includes the steps of: (a) providing an upper half shell formed from a polymer; (b) providing a lower half shell formed from a polymer; (c) providing a one piece inner shell formed from a polymer; (d) disposing the one piece inner shell in one of the lower half shell and the upper half shell; (e) subsequent to step (d), joining the one piece inner shell to the one of the lower half shell and the upper half shell; and (f) joining the one piece inner shell to the other one of the lower half shell and the upper half shell to thereby produce the composite air intake manifold assembly, wherein the one piece inner shell in combination with the upper half shell and the lower half shell cooperate to define at least a pair of spaced apart air intake runners, each of the runners including an opened air intake end, adapted to receive atmospheric air, and an opened air inlet end, adapted to be connected to an associated air inlet side of a cylinder head of the internal combustion engine.

BACKGROUND OF THE INVENTION

[0001] This invention relates in general to vehicle engines and inparticular to an improved composite intake manifold assembly for use insuch a vehicle engine and method for producing the same.

[0002] An intake manifold assembly of a multi-cylinder engine includes aplurality of branched air passageways or ducts. Each of the airpassageways defines a generally tubular runner having an air intake portand an opposite air inlet port. The air intake port of the runner isconnected to an associated plenum which supplies atmospheric, turbo, orsupercharged air to the runner intake port, and the air inlet port isconnected to a flange which is connected to an associated inlet port ofeach cylinder head of the engine to supply the air from the runner toeach cylinder head. Conventional intake manifold assemblies areconstructed of cast iron, magnesium, aluminum, and plastic.

[0003] A typical aluminum intake manifold assembly is produced entirelyby conventional casting process. These manifolds typically include aplurality of tubes disposed having first ends connected with the outletholes of an air intake plenum, and second opposite ends connected withthe associated holes of a flange member which is adapted for mounting toa cylinder head of the engine. Since the tubes are usually U-shaped, themanifold cannot be cast in one piece but rather must be cast in twosections, with one section comprising a length of the tubing castintegrally with the plenum and the other section comprising theremaining length of the tubing cast integrally with the flange member.The halves must then be joined together with bolts and a gasket or othersuitable hardware to complete the manifold, further adding to the costand complexity of the manifold.

[0004] A typical plastic multi-piece manifold assembly includes an upperhalf shell and a lower half shell which are joined together by a weldingprocess. In some instances the plastic multi-piece manifold assemblyincludes one or more inner shell pieces which are disposed within theupper and/or lower half shells. The inner shell can be lower partialinserts which are secured to lower half shell; upper partial insertswhich are secured to the upper half shell, or both lower and upperpartial inserts which are secured to the respective lower and upper halfshells. The inserts are typically joined to the associated half shell bya conventional heat staking process or welding process. In someinstances, a plurality of individual blow molded tubes are disposedwithin the upper and lower half shells and joined thereto by aconventional heat staking process. In both types of constructions, theinserts or the inserts in cooperation with upper or lower half shellsdefine a corresponding number of runner paths through which air issupplied to the associated cylinder head of the engine.

SUMMARY OF THE INVENTION

[0005] This invention relates to an improved composite air intakemanifold assembly adapted for use with an internal combustion engine andmethod for producing the same. The composite air intake manifoldassembly includes an upper half shell formed from a polymer, a lowerhalf shell formed from a polymer and joined to the upper half shell todefine a housing having an internal cavity, and a one piece inner shellformed from a polymer and disposed within the cavity. The one pieceinner shell in combination with the upper half shell and the lower halfshell cooperate to define at least a pair of spaced apart air intakerunners. Each of the runners includes an opened air intake end adaptedto receive atmospheric air, and an opened air inlet end adapted to beconnected to an associated air inlet side of a cylinder head of theinternal combustion engine. The method for producing the composite airintake manifold assembly includes the steps of: (a) providing an upperhalf shell formed from a polymer; (b) providing a lower half shellformed from a polymer; (c) providing a one piece inner shell formed froma polymer; (d) disposing the one piece inner shell in one of the lowerhalf shell and the upper half shell; (e) subsequent to step (d), joiningthe one piece inner shell to the one of the lower half shell and theupper half shell; and (f) joining the one piece inner shell to the otherone of the lower half shell and the upper half shell to thereby producethe composite air intake manifold assembly, wherein the one piece innershell in combination with the upper half shell and the lower half shellcooperate to define at least a pair of spaced apart air intake runners,each of the runners including an opened air intake end, adapted toreceive atmospheric air, and an opened air inlet end, adapted to beconnected to an associated air inlet side of a cylinder head of theinternal combustion engine. The one piece inner shell of the air intakemanifold assembly of this invention can be formed for a variety ofdifferent vehicle engine applications. As a result of this, variousrunner lengths and plenum volumes of the air intake manifold assemblycan be attained by only modifying the one piece inner shell of thepresent invention.

[0006] Other advantages of this invention will become apparent to thoseskilled in the art from the following detailed description of thepreferred embodiments, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]FIG. 1 is a perspective view of a first embodiment of a compositeintake manifold assembly constructed in accordance with the presentinvention.

[0008]FIG. 2 is a plan view of an upper half shell used in the compositeintake manifold assembly illustrated in FIG. 1.

[0009]FIG. 2A is an enlarged plan view of a portion of the upper halfshell shown in FIG. 2.

[0010]FIG. 3 is a plan view of a lower half shell used in the compositeintake manifold assembly illustrated in FIG. 1.

[0011]FIG. 3A is an enlarged plan view of a portion of the lower halfshell shown in FIG. 3.

[0012]FIG. 4 is a perspective view of a one piece inner shell used inthe composite intake manifold assembly illustrated in FIG. 1.

[0013]FIG. 4A is an enlarged view of a portion of the one piece innershell shown in FIG. 4.

[0014]FIG. 5 is a plan view of the one piece inner shell illustrated inFIGS. 1 and 4.

[0015]FIG. 5A is an enlarged plan view of a portion of the one pieceinner shell shown in FIG. 5.

[0016]FIG. 6 is a sectional view of the composite intake manifoldassembly illustrated in FIG. 1.

[0017]FIG. 7 is a sectional view of the composite intake manifoldassembly taken along line 7-7 of FIG. 6.

[0018]FIG. 8 is a sectional view of the composite intake manifoldassembly taken along line 8-8 of FIG. 6.

[0019]FIG. 9 is a sectional view of the composite intake manifoldassembly taken along line 9-9 of FIG. 6.

[0020]FIG. 10 is a sectional view of the composite intake manifoldassembly taken along line 10-10 of FIG. 6.

[0021]FIG. 11 is a sectional view of the composite intake manifoldassembly taken along line 11-11 of FIG. 6.

[0022]FIG. 12 is a sectional view of the composite intake manifoldassembly taken along line 12-12 of FIG. 6.

[0023]FIG. 13 is a sectional view of the composite intake manifoldassembly taken along line 13-13 of FIG. 6.

[0024]FIG. 14 is a perspective view of an alternate embodiment of apartial inner shell which can be used in connection with the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] Referring now to the drawings, there is illustrated in FIG. 1 aperspective view of a first embodiment of a composite air intakemanifold assembly, indicated generally at 10, in accordance with thepresent invention. The composite intake manifold assembly 10 shown inthis embodiment is for use with a V-8 engine and includes a cover 12, anupper half shell 14, a one piece “full” inner shell or insert 16, and alower half shell 18. As will be discussed below, the cover 12, the upperhalf shell 14, the one piece inner shell 16, and the lower half shell 18are joined together and sealed by a suitable process to produce thecomposite intake manifold assembly 10 in accordance with this invention.

[0026] Preferably, the process used to form the composite intakemanifold assembly 10 of this invention is a welding process. Morepreferably, the welding process is a linear vibration welding process.However, other suitable welding process which are operative to “heat”the surfaces causing the melting and/or fusing together of the surfacescan be used if desired. Preferably, such welding processes cause heat atthe associated surfaces to create friction therebetween and cause thesurfaces to be joined together by melting and/or fusing. However,welding processes which do not create friction between the adjacentsurfaces but which are still effective to create heat between thesurfaces to join them together can be used. For example, suitablefriction welding processes can include an ultrasonic welding process, anon-linear vibration welding process, and a hot plate welding process;suitable non-friction welding processes can include laser or infraredprocesses. In addition, as will be discussed below, different processescan be used for the joining of the components of the air intake manifoldassembly 10 of this invention and the sealing of the components thereof.

[0027] Preferably, the cover 12, the upper half shell 14, the one pieceinner shell 16, and the lower half shell 18 of the composite intakemanifold assembly 10 are all formed of the same material. Such asuitable material is a glass reinforced nylon. Alternatively, othersuitable materials can be used and/or the materials of one or more ofthe cover 12, the upper half shell 14, the one piece inner shell 16, andthe lower half shell 18 can be different than the others. For example,other suitable materials can include unreinforced nylon and mineralreinforced nylon. Although the composite intake manifold assembly 10illustrated and described herein is for use with a V-8 engineapplication, it will be appreciated that the invention can be used inconjunction with other types of engines. For example, the compositemanifold assembly can be used in connection with an inline 4 cylinderengine (I-4), an inline 6 cylinder engine (I-6), and a V-6 cylinderengine.

[0028] As shown in FIG. 1, the cover 12 is a molded cover formed from asuitable plastic material and includes a plurality of integrally moldedin place vacuum taps (two of such taps illustrated in this embodiment atreference numbers 20 and 22). The cover 12 includes an outer peripheraledge 26 which defines an underside insertion or connecting flange 28.Alternatively, the shape and/or the structure of the cover 12 can beother than illustrated depending upon the particular structure of theassociated intake manifold assembly. The upper half shell 14 is a onepiece molded half shell formed from a polymer material and includes aplenum or air intake chamber 30 and eight generally tubular shaped upperrunners 32, 34, 36, 38, 40, 42, 44, and 46. Each of the runners 32, 34,36, 38, 40, 42, 44, and 46 includes a respective generally arch likeinner surface 32A, 34A, 36A, 38A, 40A, 42A, 44A, and 46A, shown in FIG.7, which defines an associated upper runner inner wall surface.

[0029] The upper half shell 14 includes a flange 48 having an opening 50formed therein. The flange 48 is adapted to be connected to a throttlebody (not shown) and the opening 50 functions as an air intake port tosupply atmospheric air to the plenum 30. The upper half shell 14 furtherincludes an opening 52 which generally corresponds to the profile of theflange 28 of the cover 12. The opening 52 defines a receiving flange 54which is adapted to receive the insertion flange 28 of the cover 12 in amating relationship therewith. Alternatively, the cover 12 could beeliminated and the upper half shell 14 could include an integrallymolded cover (not shown).

[0030] The upper half shell 14 includes an outer peripheral edge 60which defines a pair of opposed side flanges 56 and 58 and a pair ofopposed end flanges 66 and 68, best shown in FIG. 2. The side flange 56includes five mounting holes 70, and the side flange 58 includes fivemounting holes 72. As will be discussed below, the mounting holes 70 and72 are adapted to receive a suitable fastener (not shown) for securingthe composite intake manifold assembly 10 to a flange (not shown) of thecylinder heads (not shown) of an engine (not shown) thereby connectingeach of the runners of the manifold assembly to a respective inlet ofeach cylinder head.

[0031] The upper half shell 14 further includes a pair of side flanges62 and 64 which are spaced inwardly relative to side flanges 56 and 58,respectively. As will be discussed below, the side flanges 62 and 64 andthe end flanges 66 and 68 cooperate to define a continuous weldingperiphery or border around the edge 60 of the upper half shell 14(partially shown in FIG. 2A by dashed line W1), for securing the upperhalf shell 14 to the one piece inner shell 16. The upper half shell 14further includes a plurality of receiving flanges F1-F9, shown in FIG.2. As will be discussed below, each of the receiving flanges F1-F9 ofthe upper half shell 14 are adapted to receive an associated one of aplurality of insertion flanges provided on the one piece inner shell 16.

[0032] In the illustrated embodiment, the upper half shell 14 furtherincludes an integrally molded in place mounting bracket 80 (shown inFIGS. 6 and 12), and an integrally molded in place threaded sensorfitting connection 82 (shown in FIGS. 6 and 12). The mounting bracket 80is adapted to secure throttle and cruise control cables (not shown)thereto. In the illustrated embodiment, the sensor fitting connection 82is adapted to secure a charge air temperature (CAT) fitting with a turnand lock retaining feature.

[0033] The upper half shell 14 further includes eight air inlet ports32B, 34B, 36B, 38B, 40B, 42B, 44B, and 46B. As will be discussed below,the air inlet ports 32B, 34B, 36B, 38B, 40B, 42B, 44B, and 46B areadapted to be connected to an associated inlet port of each cylinderhead of the engine to supply the air from a respective one of therunners to an associated cylinder. The lower half shell 18 is a onepiece molded half shell formed from a polymer material and includeseight generally tubular shaped upper runners 132, 134, 136, 138, 140,142, 144, and 146. Each of the runners 132, 134, 136, 138, 140, 142,144, and 146 includes a respective arch like inner surface 132A, 134A,136A, 138A, 140A, 142A, 144A, and 146A, shown in FIG. 7, which define anassociated lower runner inner wall surface.

[0034] The lower half shell 18 includes an outer peripheral edge 160which defines a pair of opposed side flanges 162 and 164 and a pair ofopposed end flanges 166 and 168. As will be discussed below, the sideflanges 162 and 164 and the end flanges 166 and 168 cooperate to definea continuous welding periphery or border around the edge 160 of thelower half shell 18 (partially shown in FIG. 3A by dashed line X1), forsecuring the lower half shell 18 to the one piece inner shell 16. As canbe seen, in this embodiment the upper half shell welding periphery W1and the lower half shell welding periphery X1 are generally the same.However, the welding peripheries W1 and X1 can be other than illustratedif desired. The lower half shell 18 further includes an opening 130which is in fluid communication with the plenum 30 of the upper halfshell 14. The lower half shell 18 further includes a plurality ofreceiving flanges G1-G9, shown in FIG. 3. As will be discussed below,each of the flanges G1-G9 of the lower half shell 18 are adapted toreceive a corresponding one of a plurality of insertion flanges providedon the one piece inner shell 16.

[0035] In the illustrated embodiment, the one piece inner shell 16 is aone piece molded shell formed from a polymer material and includes eightgenerally tubular shaped runner centers 232, 234, 236, 238, 240, 242,244, and 246. As will be discussed below, the one piece inner shellrunner centers 232, 234, 236, 238, 240, 242, 244, and 246 in combinationwith the respective upper half shell runner inner wall surfaces 32A,34A, 36A, 38A, 40A, 42A, 44A, and 46A and lower half shell runner innerwall surfaces 32A, 34A, 36A, 38A, 40A, 42A, 44A, and 46A define eightrunners R1, R2, R3, R4, R5, R6, R7, and R8 (only one of such runners R4is illustrated in detail in FIG. 13), of the composite intake manifoldassembly 10. While only runner R4 is illustrated in detail in FIG. 13,it is understood that the other runners R1-R3 and R5-R8 are essentiallythe same as runner R4. FIG. 8 is a partial sectional view showing runnerR1, and FIG. 9 is a partial sectional view showing runner R2 in detail.

[0036] The one piece inner shell 16 includes an outer peripheral edge260 which defines a pair of opposed side flanges 262 and 264 and a pairof opposed end flanges 266 and 268. The side flange 262 includes anupper side flange surface 262A and a lower side flange surface 262B, andthe side flange 264 includes an upper side flange surface 264A and alower side flange surface 264B. The end flange 266 includes an upper endflange surface 266A and a lower end flange surface 267B, and the endflange 268 includes an upper end flange surface 268A and a lower endflange surface 268B.

[0037] As will be discussed below, the upper side flange surfaces 262Aand 264A and the upper end flange surfaces 266A and 268A cooperate todefine a continuous welding periphery or border around an upper edge 260of the one piece inner shell 16 (partially shown in FIGS. 3A and 4A bydashed line Y1), for securing the one piece inner shell 16 to the upperhalf shell 114; and the lower side flange surfaces 262B and 264B and thelower end flange surfaces 266B and 268B cooperate to define a continuouswelding periphery or border (not shown but similar to welding peripheryshown by dashed line Y1 described above) around a lower edge 260 of theone piece inner shell 16 for securing the one piece inner shell 16 tothe lower half shell 18. The one piece inner shell 16 further includes amain air collection chamber 230 which is operative to supply air fromthe plenum 30 to each of the runners R1, R2, R3, R4, R5, R6, R7, and R8of the intake manifold assembly 10. In FIG. 10, the main air collectionchamber 230 is shown supplying air to runners R7 and R8.

[0038] Each of the runner centers 232, 234, 236, 238, 240, 242, 244, and246 includes a respective air intake port, indicated generally at 232A,234A, 236A, 238A, 240A, 242A, 244A, and 246A, and a respective airoutlet port, indicated generally at 232B, 234B, 236B, 238B, 240B, 242B,244B, and 246B. The air intake ports 232A, 234A, 236A, 238A, 240A, 242A,244A, and 246A are in fluid communication with the main air collectionchamber 230, and the air outlet ports 232B, 234B, 236B, 238B, 240B,242B, 244B, and 246B are in fluid communication with an associated oneof the air inlet ports 32B, 34B, 36B, 38B, 40B, 42B, 44B, and 46B of theupper half shell 14.

[0039] The one piece inner shell 16 further includes a plurality oflongitudinal insertion flanges F1′-F9′ provided on the upper portionthereof, and a plurality of longitudinal insertion flanges G1′-G9′provided on the lower portion thereof. As best shown in FIGS. 4 and 5,the insertion flange F3′ is defined by a portion of an insertion flangeF3A′ of runner center 234 and a portion of an insertion flange F3B′ ofrunner center 236. Insertion flanges F5′, F7′, G3′, G5′, and G7′ have asimilar construction to that of insertion flange F3′. As will bediscussed below, the insertion flanges F1′-F9′ and G1′-G9′ of the onepiece inner shell 16 are adapted to be received into respectivereceiving flanges F1-F9 and G1-G9 of the upper half shell 14 and thelower half shell 18, shown in FIG. 7 and in FIG. 12. Alternatively,insertion flanges could be provided on the upper half shell 14 and thelower half shell 18 and receiving flanges adapted to receive suchinsertion flanges could be provided on the one piece inner shell 16.

[0040] To assemble the components together to produce the intakemanifold assembly 10, the following process occurs. First, the cover 12is positioned adjacent the upper half shell 14 by aligning the undersideinsertion flange 28 of the cover 12 with the receiving flange 54 of theupper half shell 14. Next, a linear vibration welding process ispreferably used to permanently secure the cover 12 to the upper halfshell 14. The weld used to secure the cover 12 to the upper half shell14 is both a structural weld and a sealing flange.

[0041] Following this, the one piece inner shell 16 is properlypositioned and aligned within the upper half shell 14 so that the sideand end flanges 62, 64, 66, and 68 of the upper half shell 14 aredisposed adjacent the respective upper side and end flanges 262A, 264A,266A, and 268A of the one piece inner shell 16. In addition, thereceiving flanges F1-F9 of the upper half shell 14 and the associatedinsertion flanges F1′ F9′ of the one piece inner shell 16 are disposedin a mating and/or interlocking relationship therewith.

[0042] With the one piece inner shell 16 maintained in this position,preferably a vibration welding process is used to permanently secure theone piece inner shell 16 to the upper half shell 14. In particular, theupper half shell 14 and the one piece inner shell 16 are welded togetheralong their associated weld planes or joints W1 and Y1 to provide astructural weld to join the components together and also to provide a“sealing” connection or weld between the components (welds W1 and Y1partially shown in FIG. 2A and FIGS. 4A and 5A, respectively). Inaddition, the upper half shell 14 and the one piece inner shell 16 arewelded along the F2-F9 and F2′-F9′, respectively, to provide a sealingweld therebetween (only welds W2 and W3 of the upper half shell 14 atflanges F2 and F3 illustrated in FIG. 2A, and only welds Y2 and Y3 ofthe insert illustrated in FIGS. 4A and 5A). As a result, each of theindividual runners R1-R8 in the upper half shell portion of the intakemanifold assembly 10 is completely sealed off from fluid communicationwith an associated adjacent runner. While in this embodiment a weld isnot illustrated at flanges F1 and F1′, a weld can be provided alongthese flanges or along any other flanges depending upon the particularstructure of the associated upper half shell 14 and one piece innershell 16.

[0043] Next, the lower half shell 18 is properly positioned and alignedwithin the partially assembled air intake manifold assembly so that theside and end flanges 162, 164, 166, and 168 of the lower half shell 18are disposed adjacent the respective lower side and end flanges 262B,264B, 266B, and 268B of the one piece inner shell 16. In addition, thereceiving flanges G1-G9 of the lower half shell 18 and the associatedinsertion G1′ G9′ of the one piece inner shell 16 are disposed in amating and/or interlocking relationship therewith.

[0044] With the lower half shell 18 maintained in this position,preferably a vibration welding process is used to permanently secure theinsert lower half shell 18 to the partly assembled air intake manifoldassembly and to produce the air intake manifold assembly 10 of thisinvention. In particular, the lower half shell 18 and the one pieceinner shell 16 are welded together along their associated weld planes orjoints to provide a structural weld (only weld X1 of the lower halfshell 18 illustrated in FIG. 3A) to join the components together andalso to provide a “sealing” weld between the components. In addition,the lower half shell 18 and the one piece inner shell 16 are welded orotherwise connected along the flanges G1-G9 and G1′-G9′, respectively,to provide a sealing weld therebetween (only welds X2, X3 and X4 of thelower half shell 18 at flanges G1, G2 and G3 illustrated in FIG. 2A, nowelds shown for one piece inner shell 16 but are similar to those weldsY2 and Y3 of the one piece inner shell 16 illustrated in FIGS. 4A and5A). As a result, each of the individual runners R1-R8 in the lower halfshell portion of the intake manifold assembly 10 is completely sealedoff from fluid communication with an associated adjacent runner.Alternatively, if it is not desired to seal off a runner from anassociated adjacent runner, or if a different type of insert is used (aswill be discussed below in connection with FIG. 14), or if no insert isused at all, only the “structural” weld along the associated flanges 62,64, 66, 68 and 162, 164, 166, and 168 of the upper half shell 14 and thelower half shell 18 may be needed. Also, the structure of the receivingflanges F1-F9 and G1-G9 of the upper half shell 14 and the lower halfshell 18, respectively, and/or the structure of the insertion flangesF1′-F9′ and G1′-G9′ of the one piece inner shell 16 can be other thanillustrated if desired. If however it is desired to prevent air leakagefrom adjacent runners, the structure of such flanges should be such thatthey are in relatively close proximity with one another to allow them tobe joined together to provide a seal therebetween.

[0045] As discussed above, FIG. 13 illustrates runner R4 in detail. Asshown therein, runner R4 functions to supply air from main chamber 230,to air inlet port 138A, in the direction of the arrows, to air outletport 138B, and to air inlet port 38B. Also, since the runner center 234of the one piece inner shell 16 is sealed along all adjacent surfaces ofthe upper half shell 14 and the lower half shell 18, all the airentering runner R4 from port 138A is supplied to port 38B without anyair leakage to the adjacent runners R3 and R5. Thus, a “360 degree” wrapweld joint is created in runner R4, as well as the other runners R1-R3and R5-R8. The term 360 degree wrap weld joint as used herein refers tothe fact that the associated runner is completely sealed around itsentire arch shaped path from an adjacent runner, the path being definedfrom the air inlet port of the runner to the associated air outlet portthereof in a generally full circular path (i.e., a 360 degree likepath). As a result, there is no air leakage from one runner to anadjacent runner, and the air supplied to each associated cylinder headis maintained uniform.

[0046]FIG. 14 illustrates an alternate embodiment of a partial innershell or insert, indicated generally at 316, which can be used in placeof the one piece full inner shell 16. The partial inner shell 316includes flanges 318, 320, 322, 324, and 326. The flanges 318, 320, 322,324, and 326 are provided with respective openings 318A, 320A, 322A,324A, and 326A. The openings 318A, 320A, and 322A are operative toenable the partial inner shell 316 to be joined to the associated upperhalf shell 14 or lower half shell 18 by an appropriate method, such asfor example, by heat staking. The openings 324A and 326A are operativeto enable additional inserts (not shown) to be connected to the partialinner shell 316. The number of partial inner shells 316 which are usedis dependent upon the particular vehicle application.

[0047] One advantage of the air intake manifold assembly 10 illustratedin FIGS. 1-13 is that the runners R1-R8 are completely sealed off fromfluid communication with each adjacent runner to prevent air leakagefrom one runner to an adjacent runner. As a result of this, the airsupplied to each associated cylinder head from the air intake manifoldassembly 10 of this invention is maintained at a desired generallyconstant flow rate. Another advantage of the air intake manifoldassembly 10 illustrated in FIGS. 1-13 is that the one piece inner shell16 can be formed for a variety of different vehicle engine applications.As a result of this, various runner lengths and plenum volumes can beattained by only modifying the one piece inner shell 16 of the presentinvention. Yet another advantage of this invention is that the one pieceinner shell 16 allows a generally arch shaped runner with a greater than180 degrees wrap. Still a further advantage of the air intake manifoldassembly 10 of this invention is that a generally “straight” weld isused to connect the side flanges 62 and 162 and 64 and 164 of associatedupper half shell 14 and the lower half shell 18. This straight weld canbe used with the one piece full inner shell 16 illustrated in FIGS. 1,4, 4A, 5, 5A, and 7-13, the insert 316 illustrated in FIG. 14, or withno inner shell at all. In addition, a straight weld could be used toconnect the side flanges 62 and 162 and 64 and 164, and a separatestructural and/or sealing weld could be used with the inner shell orinner shells. In either of the above structures, as a result of thisgenerally straight weld, the associated “burst pressure strength” of theair intake manifold assembly 10 is increased. Thus, the air intakemanifold assembly 10 of this invention can eliminate the need ofproviding a costly blow off safety valve. Still a further advantage ofthe air intake manifold assembly 10 of this invention is that the upperhalf shell 14 includes an integrally molded in place mounting bracket80, sensor fitting connection 82, and vacuum taps 20 and 22. As a resultof this, the costs associated with the brass fitting typically used forthe connection and taps can be eliminated.

[0048] In accordance with the provisions of the patents statues, theprinciple and mode of operation of this invention have been describedand illustrated in its preferred embodiments. However, it must beunderstood that the invention may be practiced otherwise than asspecifically explained and illustrated without departing from the scopeor spirit of the attached claims.

What is claimed is:
 1. A composite air intake manifold assembly adaptedfor use with an internal combustion engine comprising: an upper halfshell formed from a polymer; a lower half shell formed from a polymerand joined to said upper half shell to define a housing having aninternal cavity; and a one piece inner shell formed from a polymer anddisposed within said cavity, said inner shell in combination with saidupper half shell and said lower half shell cooperating to define atleast a pair of spaced apart air intake runners, each of said runnersincluding an opened air intake end, adapted to receive atmospheric air,and an opened air inlet end, adapted to be connected to an associatedair inlet side of a cylinder head of the internal combustion engine. 2.The composite air intake manifold assembly defined in claim 1 whereinsaid upper half shell is joined to said lower half shell by a weldingprocess, and said one piece inner shell is disposed within said cavityand joined to said upper half shell and said lower half shell by awelding process.
 3. The composite air intake manifold assembly definedin claim 1 wherein said one piece inner shell includes at least twogenerally tubular shaped runner centers which in combination with aninner runner wall surface of said upper half shell and an inner wallsurface of said lower half shell cooperate to define at least a pair ofspaced apart generally tubular shaped air intake runners.
 4. Thecomposite air intake manifold assembly defined in claim 1 wherein saidone piece inner shell includes an outer peripheral edge which defines apair of opposed side flanges and a pair of opposed end flanges, each ofsaid side flanges including an upper side flange surface and a lowerside flange surface, each of said end flanges including an upper endflange surface and a lower end flange surface, said upper side flangesurfaces and said upper end flange surfaces defining a continuouswelding periphery around an upper edge of said one piece inner shell forjoining said one piece inner shell to said upper half shell, and saidlower side flange surfaces and said lower end flange surfaces defining acontinuous welding periphery around a lower edge of said one piece innershell for joining said one piece inner shell to said lower half shell.5. The composite air intake manifold assembly defined in claim 1 whereinsaid one piece inner shell includes a plurality of insertion flangesprovided on the upper portion thereof, and a plurality of insertionflanges provided on the lower portion thereof, said upper half shellincludes a plurality of receiving flanges, said lower half shellincludes a plurality of receiving flanges, and said insertion flanges ofsaid inner shell are adapted to be received into said receiving flangesof said upper half shell and said lower half shell in a matingrelationship therewith so as to properly position and align said upperhalf shell, said one piece inner shell, and said lower half shellrelative to one another.
 6. The composite air intake manifold assemblydefined in claim 1 wherein said one piece inner shell includes aplurality of receiving flanges provided on the upper portion thereof,and a plurality of receiving flanges provided on the lower portionthereof, said upper half shell includes a plurality of insertionflanges, said lower half shell includes a plurality of insertionflanges, and said receiving flanges of said inner shell are adapted toreceive said insertion flanges of said upper half shell and said lowerhalf shell in a mating relationship therewith so as to properly positionand align said upper half shell, said one piece inner shell, and saidlower half shell relative to one another.
 7. The composite air intakemanifold assembly defined in claim 1 wherein said one piece inner shellin combination with said upper half shell and said lower half shellcooperating to define eight spaced apart air intake runners adapted foruse with a V-8 internal combustion engine application, each of saidrunners including an opened air intake end, adapted to receiveatmospheric air, and an opened air inlet end, adapted to be connected toan associated air inlet side of a cylinder head of the V-8 internalcombustion engine.
 8. A method for producing a composite air intakemanifold assembly adapted for use with an internal combustion enginecomprising the steps of: (a) providing an upper half shell formed from apolymer; (b) providing a lower half shell formed from a polymer; (c)providing a one piece inner shell formed from a polymer; (d) disposingthe one piece inner shell in a cavity defined by the upper half shelland the lower half shell when disposed adjacent one another; and (e)joining the one piece inner shell to the upper half shell and the lowerhalf shell and the upper half shell to the lower half shell wherein theone piece inner shell in combination with the upper half shell and thelower half shell cooperate to define at least a pair of spaced apart airintake runners, each of the runners including an opened air intake end,adapted to receive atmospheric air, and an opened air inlet end, adaptedto be connected to an associated air inlet side of a cylinder head ofthe internal combustion engine.
 9. The method according to claim 8wherein subsequent to step (d), the upper half shell is joined to thelower half shell by a welding process, and the one piece inner shell isjoined to the upper half shell and the lower half shell by a weldingprocess.
 10. The method according to claim 8 wherein the one piece innershell includes at least two generally tubular shaped runner centerswhich in combination with an inner runner wall surface of the upper halfshell and an inner wall surface of the lower half shell cooperate todefine at least a pair of spaced apart generally tubular shaped airintake runners.
 11. The method according to claim 8 wherein the onepiece inner shell includes an outer peripheral edge which defines a pairof opposed side flanges and a pair of opposed end flanges, each of saidthe flanges including an upper side flange surface and a lower sideflange surface, each of the end flanges including an upper end flangesurface and a lower end flange surface, the upper side flange surfacesand the upper end flange surfaces defining a continuous weldingperiphery around an upper edge of the one piece inner shell, the lowerside flange surfaces and the lower end flange surfaces defining acontinuous welding periphery around a lower edge of the one piece innershell, and during step (e) the upper half shell, the lower half shell,and the one piece inner shell are joined together by welding along thewelding peripheries.
 12. The method according to claim 8 wherein the onepiece inner shell includes a plurality of insertion flanges provided onthe upper portion thereof and a plurality of insertion flanges providedon the lower portion thereof, the upper half shell includes a pluralityof receiving flanges, the lower half shell includes a plurality ofreceiving flanges, and prior to step (e), the insertion flanges of theinner shell are received into the receiving flanges of the upper halfshell and the lower half shell in a mating relationship therewith so asto properly position and align the upper half shell, the one piece innershell, and the lower half shell relative to one another.
 13. The methodaccording to claim 8 wherein the one piece inner shell includes aplurality of receiving flanges provided on the upper portion thereof anda plurality of receiving flanges provided on the lower portion thereof,the upper half shell includes a plurality of insertion flanges, thelower half shell includes a plurality of insertion flanges, and prior tostep (e), the receiving flanges of the inner shell receive the insertionflanges of the upper half shell and the lower half shell in a matingrelationship therewith so as to properly position and align the upperhalf shell, the one piece inner shell, and the lower half shell relativeto one another.
 14. The method according to claim 8 wherein the onepiece inner shell in combination with the upper half shell and the lowerhalf shell cooperate to define eight spaced apart air intake runnersadapted for use with a V-8 internal combustion engine application, eachof the runners including an opened air intake end, adapted to receiveatmospheric air, and an opened air inlet end, adapted to be connected toan associated air inlet side of a cylinder head of the V-8 internalcombustion engine.
 15. A method for producing a composite air intakemanifold assembly adapted for use with an internal combustion enginecomprising the steps of: (a) providing an upper half shell formed from apolymer; (b) providing a lower half shell formed from a polymer; (c)providing a one piece inner shell formed from a polymer; (d) disposingthe one piece inner shell in one of the lower half shell and the upperhalf shell; (e) subsequent to step (d), joining the one piece innershell to the one of the lower half shell and the upper half shell; and(f) joining the one piece inner shell to the other one of the lower halfshell and the upper half shell to thereby produce the composite airintake manifold assembly, wherein the one piece inner shell incombination with the upper half shell and the lower half shell cooperateto define at least a pair of spaced apart air intake runners, each ofthe runners including an opened air intake end, adapted to receiveatmospheric air, and an opened air inlet end, adapted to be connected toan associated air inlet side of a cylinder head of the internalcombustion engine.
 16. The method according to claim 15 wherein step (e)and step (f) are done simultaneously with one another.